Device and Method for Preventing Crack Formation in a Concrete Floor

ABSTRACT

A system for preventing cracks in a concrete floor associated with a building structure, the building structure having a plurality of support columns for supporting the building structure, is provided. Each support column has a base with at least three sides and is embedded in a ground surface underneath the building structure. The system also includes one or more crack prevention members having a first surface and a second surface, an outer side wall and an inner side wall defining a cut-out portion. The crack prevention member may comprise various materials including rubber, plastic, resin, or other polymeric material and combinations thereof.

FIELD OF INVENTION

This invention generally relates to a device and method for preventing crack formation in a concrete floor. A plurality of support columns extend from the concrete floor and support the weight of a building structure.

BRIEF SUMMARY OF THE INVENTION

Disclosed herein is a system for preventing cracks in a concrete floor associated with a building structure, the building structure having a plurality of support columns for supporting the building structure. Each support column has a base with at least three sides and is embedded in a ground surface underneath the building structure. The system also includes one or more crack prevention members having a first surface and a second surface, an outer side wall and an inner side wall defining a cut-out portion. The crack prevention member may comprise various materials including rubber, plastic, resin, or other polymeric material and combinations thereof.

The base of each support column is positioned within said cut-out portion of the crack prevention member. The crack prevention member typically may comprise various geometric shapes including rectangular, square, triangular, or other polygon shape. The base of each column has a shape including square, rectangular, triangular, or other polygon shape. Each crack prevention member has a cut-out portion with a shape resembling the base of each column including rectangular, square, triangular, or other polygon shape. Thus, the cut-out portion comprises a shape and dimensions substantially similar to the base of each support column.

A concrete floor is constructed by pouring concrete to a level such that the concrete only contacts the outer side wall of the crack prevention member. Concrete does not contact the support column, and the crack prevention member remains in the concrete floor after the concrete has set or cured. When a support column is positioned adjacent a wall of the building structure, at least two corners of the support column lie adjacent to two straight sides of the crack prevention member. Further, when a support column is positioned in a corner of the building structure, at least one corner of the support column lies adjacent to at least one straight side of the crack prevention member. At least one saw cut is also provided in the concrete floor. The saw cut coincides with a corner of a first crack prevention member and extends to a corner of a second crack prevention member located opposite thereto.

Also disclosed herein is a method for preventing cracks in a concrete floor associated with a building structure. The building structure is positioned atop a ground surface, and has a plurality of support columns for supporting the building structure. The method includes the use of one or more crack prevention members having a first surface and a second surface, an outer side wall and an inner side wall defining a cut-out portion.

An initial step may include placing a plurality of crack prevention members at positions on the ground surface and positioning each support column through a crack prevention member via a cut-out portion associated with each crack prevention member. An initial step may also involve embedding each support column into a ground surface below the building structure. Subsequently, concrete is poured onto the ground surface to a level that matches the height of the crack prevention member. The concrete is allowed to set, at which time the concrete only contacts the outer side wall of the crack prevention member. The concrete does not contact the support column. Once the concrete floor has set or cured, at least one saw cut is provided in concrete floor. Each saw cut originates at a corner of a first crack prevention member and extends to a corner of a second crack prevention member located opposite thereto.

The method also includes the requirement that when a support column is positioned in a corner of the building structure, at least two corners of the support column lie adjacent to at least two straight sides of the crack prevention member and when a support column is positioned in a corner of the building structure, at least one corner of the support column lies adjacent to at least one straight side of the crack prevention member. The crack prevention member remains in the concrete floor after the concrete has set.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an example of cracking that may occur in concrete floors associated with a building structure.

FIG. 2 shows one embodiment of a system for preventing cracks in concrete floor of a building structure.

FIGS. 3a and 3b show a system for preventing cracks in concrete floors including a perspective view of a crack prevention member.

FIGS. 4a and 4b provide respective top views of two crack prevention members with two cut-out portions that vary with respect to geometric shape.

FIGS. 5a and 5b provide plan views of a concrete floor of a building structure with crack prevention members which may be utilized in the present invention.

FIG. 6 shows an alternative embodiment of a crack prevention member.

DETAILED DESCRIPTION

Referring to FIG. 1, the figure shows a concrete floor that has undergone cracking caused by shrinkage, frost heave, or excessive weight. Cracking in concrete is not only aesthetically unappealing, but may also compromise the structural integrity of a patio, garage, or other similar building structure associated with the concrete floor. In particular, where the cracks appear around a support column as shown, this may weaken the support column's weight-bearing capacity and lead to building code violations, or worse yet, safety concerns. In cold climates frost could lift the post, which can heave the floor if the concrete is touching that post or column. Therefore, there is a need for a device that keeps a concrete floor isolated from an outside post, particularly in cold climates.

FIG. 2 shows a system for preventing cracks in a concrete floor 12 of a building structure 14. The system comprises a plurality of support columns 18, each positioned within a crack prevention member 10. Each support column 18 is embedded at its base 18 a within a ground surface 16. Ground surface 16 is located underneath building structure 14 and concrete floor 12, which is positioned atop ground surface 16. A top end 18 b of support column 18 is positioned adjacent a roof 19 of building structure 14. Each crack prevention member 10 comprises a first surface 10 a, a second surface 10 b, at least two outer side walls 10 c-10 d, and at least one inner side wall 10 e-10 g, as well as a cut-out portion 15. The base 18 a of each support column 18 is positioned within a cut-out portion 15. Support column 18 and crack prevention member 10 may be positioned adjacent an outer skirt board 21 of building structure 14, which is placed along a lower wall of building structure 14. Skirt board 21 typically runs about 2-4 inches in depth and about 12 inches in height. Two or more kicker studs 23 may extend at an angle from each support column 18, for providing supplementary bracing to support column 18 and building structure 14. Each support column 18 typically comprises a 6×6 inch treated post.

Crack prevention member 10 may comprise a rectangular, square, triangular or other polygon shape, and is typically made from rubber, plastic, resin, or other similar polymeric material as well as combinations thereof. The polymeric material of crack prevention member 10 may further include metal, graphite, ceramic, or other similar substances, which enhance the toughness and thermal properties of crack prevention member 10. Outer side walls 10 c-10 d and inner side walls 10 e-10 g of crack prevention member 10 may be about 2 to 6 inches in height. When concrete floor 12 is under construction, concrete is poured to a level such that the concrete contacts outer side walls 10 c-10 d of crack prevention member 10, but concrete does not contact support column 18.

FIG. 3A shows how crack prevention member 10 may be fastened to an outer skirt board 21. In particular, outer side walls 10 c-10 d of crack prevention member 10 may be fastened to outer skirt board 21 via a fastening means 24. Fastening means 24 may comprise bolts, pins, screws, nails, studs, or other similar fastening means known in the art. FIG. 3B is a perspective view of crack prevention member 10 showing outer side walls 10 c-10 d, inner side walls 10 e-10 g, and cut-out portion 15. In particular, FIG. 3B shows that cut-out portion 15 extends through first surface 10 a and second surface 10 b of crack prevention member 10 thereby exposing inner side walls 10 e-10 g. As shown in FIG. 3B, cut-out portion 15 has three sides coinciding with inner side walls 10 e-10 g and a fourth side 15 a, which is open. This fourth open side 15 a, facilitates the insertion of support column 18 within cut-out portion 15. The base of each support column 18 a comprises a shape including square, rectangular, triangular, or other polygon shape. Similarly, cut-out portion 15 comprises a shape and dimensions substantially similar to base 18 a of each support column 18.

FIGS. 4A and 4B provide respective perspective and top views of crack prevention member 10. In particular, FIG. 4A shows crack prevention member 10 comprises outer side walls 10 c-10 d. Here, support column 18 is square-shaped measuring approximately 5-7 inches on each side thereof. Support column 18, is positioned within cut-out portion 15 and may be any size as long as its size correlates with the dimensions of each support column's base 18 a. In FIG. 4B, a rectangular support column 18 is illustrated. As with the example shown in FIG. 4A, the sides of cut-out portion 15 may be any size as long as the dimensions of cut-out portion 15 coincides with the dimensions of support column base 18 a. FIGS. 4A and 4B also show each crack prevention member 10 may also comprise a chalk line head holder 25. Chalk line head holder 25 allows attachment of a chalk line to each crack prevention member 10 in order to facilitate proper alignment of each crack prevention member 10 as well as a plurality of saw cuts 28 as discussed below.

FIGS. 5A and 5B provide large area views of concrete floor 12 having crack prevention members 100 distributed thereon. Concrete floor 12 is utilized as part of a building structure 14 such as a garage, which may comprise a plurality of planar side walls 30. In particular, FIG. 5A shows crack prevention member 100 a may be positioned adjacent a planar side wall 30 a. In addition, crack prevention member 100 b may be positioned where two planar side walls 30 a meet forming a corner 30 b, and crack prevention member 100 c may be positioned near a doorway 30 c of the building structure. Each crack prevention member 100 comprises cut-out portion 15 with a support column (not shown) positioned therein. Each support column is embedded in ground surface 16 below concrete floor 12 in order to support the weight of the building structure 14. FIG. 5B shows that when a support column 18 is positioned adjacent planar side wall 30 a of a building structure, that at least two corners 18 c and 18 d of the support column 18 lie adjacent two straight sides of crack prevention member 100. In contrast, when a support column 18 is positioned in a corner 30 b of building structure 14, at least one corner 18 e thereof lies adjacent at least one straight side of crack prevention member 100. FIGS. 5A and 5B also show concrete floor 12 having a plurality of saw cuts 28. As shown in FIG. 5A, saw cuts 28 are cut into the concrete of concrete floor 12. Saw cuts 28 extend from a pointed edge 11 a of a first crack prevention 100 to pointed edge 11 b of a second crack prevention member 100 located directly opposite first crack prevention member 100. The purpose of saw cuts 28 is to alleviate stress and provide a further means of preventing random cracks of concrete floor 12.

FIG. 6 shows an alternative embodiment of a crack prevention member 200. In particular, crack prevention member 200 of FIG. 6 may be utilized in a central portion of a concrete floor 12. FIG. 6 contemplates three different embodiments of centrally-located crack prevention member 200. In a first embodiment, crack prevention member 200 may comprise two equilateral triangles, each having a rectangular cut-out portion 15 cut therein. In this embodiment, when the base of each equilateral triangle are positioned adjacently, a single square-shaped cut-out portion 15 results. In a second embodiment, four equilateral triangles are assembled so as to surround support column 180. Two of the four triangles may be of one size and the other two triangles may be of a different size.

As shown in FIG. 6, support column 180 is positioned such that each corner 180 a-180 d of support column 180, lies adjacent a straight side of crack prevention member 200. In addition, as in FIGS. 5A and 5B, saw cuts 28 are cut into the concrete of concrete floor 12 after the concrete has set. Each saw cut 28 emanates from each pointed edge 11 of crack prevention member 200 in order to control cracking of concrete floor 12.

The present crack prevention system also contemplates a method for preventing cracks in a concrete floor 12 associated with a building structure 14. FIG. 2 shows concrete floor 12 of a building structure 14. Each support column 18 is embedded near its base 18 a within ground surface 16. Ground surface 16 is located underneath building structure 14 and concrete floor 12, which is positioned atop ground surface 16. A top end 18 b of support column 18 is positioned adjacent a roof 19 of building structure 14.

The first step in the method of preventing cracks in a concrete floor involves placing a plurality of crack prevention members 10 at various positions on a ground surface 16. Each crack prevention member 10 comprises first surface 10 a, second surface 10 b, at least two outer side walls 10 c-10 d, and at least one inner side wall 10 e-10 g, as well as a cut-out portion 15. The second step entails placing the base 18 a of each support column 18 within the cut-out portion 15 of each crack prevention member 10 and into the ground surface 16 such that each support column 18 is embedded into ground surface 16. Support column 18 and crack prevention member 10 may be positioned adjacent an outer skirt board 21 of building structure 14, which is placed along a lower wall of building structure 14. Outer skirt board 21 typical runs about 2-4 inches in depth and about 12 inches in height. Two or more kicker studs 23 may extend at an angle from each support column 18, for providing supplementary bracing to support column 18 and building structure 14. Each support column 18 typically comprises a 6×6 inch treated post.

A further step in the method as shown in FIG. 5A involves positioning crack prevention members 100 a adjacent planar side walls 30 a, positioning crack prevention members 100 b where two planar side walls 30 a meet forming corner 30 b, and positioning crack prevention members 100 c near a doorway 30 c of building structure 14. Each type of crack prevention member 100, comprises cut-out portion 15 with a support column (not shown) positioned therein. Each support column 18 is embedded in ground surface 16 below concrete floor 12 in order to support the weight of the building structure 14.

The next step in the method is illustrated in FIG. 5B. When support column 18 is positioned adjacent planar side wall 30 a of a building structure, support column 18 is positioned such that at least two corners 18 c and 18 d thereof lie adjacent two straight sides of crack prevention member 100. In contrast, when a support column 18 is positioned in a corner 30 b of a building structure, at least one corner 18 c of support column 18 lies adjacent at least one straight side of crack prevention member 100.

Next, concrete is poured to a level such that concrete contacts the outer side walls of crack prevention member 100, but concrete does not contact support columns 18. Following this step, the concrete is allowed to set. Once the concrete has cured, the concrete contacts the outer side walls of crack prevention member 100, but the concrete does not contact any part of the support columns 18.

A final step in the method is shown in FIGS. 5A. A plurality of saw cuts 28 are cut into the concrete of concrete floor 12 subsequent to its curing. Saw cuts 28 extend from a pointed edge 11 a of a first crack prevention member 100 to pointed edge 11 b of a second crack prevention member 100 located directly opposite from first crack prevention member 100. Saw cuts 28 alleviate stress and provide a further means of preventing random cracks of concrete floor 12. 

1. A system for preventing cracks in a concrete floor associated with a building structure, the building structure having a plurality of support columns for supporting the building structure, each support column embedded in a ground surface underneath the building structure and having a base and at least three sides, the system comprising: one or more crack prevention members having a first surface and a second surface, an outer side wall and an inner side wall defining a cut-out portion, the base of each support column positioned within said cut-out portion of the crack prevention member; wherein the concrete floor is poured to a level such that the concrete only contacts the outer side wall of the crack prevention member and does not contact the support column, wherein the crack prevention member remains in the concrete floor after the concrete has set.
 2. The system for preventing cracks in a concrete floor associated with a building structure of claim 1, wherein said crack prevention member has a shape including rectangular, square, triangular, or other polygon shape.
 3. The system for preventing cracks in a concrete floor associated with a building structure of claim 1, wherein the cut-out portion has a shape including rectangular, square, triangular, or other polygon shape.
 4. The system for preventing cracks in a concrete floor associated with a building structure of claim 1, wherein the base of each column has a shape including square, rectangular, triangular, or other polygon shape.
 5. The system for preventing cracks in a concrete floor associated with a building structure of claim 3, wherein said cut-out portion comprises a shape and dimensions substantially similar to the base of each support column.
 6. The system for preventing cracks in a concrete floor associated with a building structure of claim 1, wherein the crack prevention member may comprise a rubber, plastic, resin, or other polymeric material and combinations thereof.
 7. The system for preventing cracks in a concrete floor associated with a building structure of claim 1, wherein when a support column is positioned adjacent a wall of the building structure, at least two corners of the support column lie adjacent to two straight sides of the crack prevention member.
 8. The system for preventing cracks in a concrete floor associated with a building structure of claim 1, wherein when a support column is positioned in a corner of the building structure, at least one corner of the support column lies adjacent to at least one straight side of the crack prevention member.
 9. The system for preventing cracks in a concrete floor associated with a building structure of claim 1, wherein at least one saw cut is provided in said concrete floor, said saw cut coinciding with a corner of the crack prevention member.
 10. A system for preventing cracks in a concrete floor associated with a building structure, the building structure having a plurality of support columns for supporting the building structure, each support column embedded in a ground surface underneath the building structure and having a base and at least three sides, the system comprising: one or more crack prevention members having a first surface and a second surface, an outer side wall and an inner side wall defining a cut-out portion, the base of each support column positioned within said cut-out portion of the crack prevention member; wherein the cut-out portion comprises a shape and dimensions substantially similar to the base of each support column.
 11. The system for preventing cracks in a concrete floor associated with a building structure of claim 10, wherein said crack prevention member has a shape including rectangular, square, triangular, or other polygon shape.
 12. The system for preventing cracks in a concrete floor associated with a building structure of claim 10, wherein the cut-out portion has a shape including rectangular, square, triangular, or other polygon shape.
 13. The system for preventing cracks in a concrete floor associated with a building structure of claim 10, wherein the base of each column has a shape including rectangular, square, triangular, or other polygon shape.
 14. The system for preventing cracks in a concrete floor associated with a building structure of claim 10, wherein the crack prevention member may comprise a rubber, plastic, resin, or other polymeric material and combinations thereof.
 15. The system for preventing cracks in a concrete floor associated with a building structure of claim 10, wherein when a support column is positioned in a corner of the building structure, at least one corner of the support column lies adjacent to at least one straight side of the crack prevention member.
 16. The system for preventing cracks in a concrete floor associated with a building structure of claim 10, wherein at least one saw cut is provided in said concrete floor, said saw cut coinciding with a corner of the crack prevention member.
 17. A method for preventing cracks in a concrete floor associated with a building structure, the building structure positioned atop a ground surface, the building structure having a plurality of support columns for supporting the building structure, each support column having a base and at least three sides, said method comprising: placing a plurality of crack prevention members at positions on the ground surface, said crack prevention member having a first surface and a second surface, an outer side wall and an inner side wall defining a cut-out portion; placing each support column through the cut-out portion of each crack prevention member and into the ground surface such that each support column is embedded into the ground surface; pouring concrete onto the ground surface to a level such that the concrete does not contact the support column and allowing the concrete to set, wherein the concrete only contacts the outer side wall of the crack prevention member; providing at least one saw cut in said concrete floor, said saw cut coinciding with a corner of the crack prevention member; wherein when a support column is positioned in a corner of the building structure, at least two corners of the support column lie adjacent to at least two straight sides of the crack prevention member and when a support column is positioned in a corner of the building structure, at least one corner of the support column lies adjacent to at least one straight side of the crack prevention member.
 18. The method for preventing cracks in a concrete floor associated with a building structure of claim 17, wherein the crack prevention member remains in the concrete floor after the concrete has set.
 19. The method for preventing cracks in a concrete floor associated with a building structure of claim 17, wherein the base of each column has a shape including rectangular, square, triangular, or other polygon shape.
 20. The method for preventing cracks in a concrete floor associated with a building structure of claim 17, wherein said cut-out portion comprises a shape and dimensions substantially similar to the base of each support column. 